Single use applicator

ABSTRACT

A single-use applicator for amorphous substances comprising a base panel impermeable to the amorphous substance, a retentive layer secured to the base panel, an amorphous substance suffused throughout the retentive layer, and a thin, flexible cover that is unaffected by the amorphous substance and secured to the base panel to seal the retentive layer in an enclosed space.

CROSS-REFERENCES TO RELATED APPLICATIONS

Not Applicable

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not Applicable

REFERENCE TO A SEQUENCE LISTING, A TABLE, OR A COMPUTER PROGRAM LISTINGCOMPACT DISK APPENDIX

Not Applicable

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to product applicators, more specifically,to applicators for greasy and/or powdered solids and amorphoussubstances such as deodorants, antiperspirants, lotions, lubricants,skin care cosmetics, medications, ointments, suntan lotions, and paints.

2. Description of the Related Art

The purpose of an applicator is to provide a user with a method forapplying a specific and/or limited amount of a substance that isdifficult or messy to handle, or that requires special packaging.Deodorants and antiperspirants, creams, lotions, lubricants, and skincare medications are examples of the former and a two-part epoxy is anexample of the later. Current applicators are typically made withoutregard to portability, disposability, and single-use application. Theserelatively large storage containers/applicators are inconvenient forpeople needing to travel with the applicator or only requiring a limitedamount of the substance on a single occasion. Existing single-useapplicators are expensive to manufacture and often contain moving parts.Some currently available single-use packages for these substances workwell for portability, but lack a tidy means for substance application.

BRIEF SUMMARY OF THE INVENTION

An object of the present invention is to provide a portable, disposable,single-use applicator for amorphous substances and the like.

The single-use applicator of the present invention has a layer ofretentive material bonded to one side of a base panel. The retentivematerial is suffused with an amorphous substance and sealing under acover. The applicator is intended for use with creams, gels, powders,and other amorphous substances.

The area of the base panel to which the retentive material is adhered isimpervious to the substance. The percentage of the base panel that holdsthe substance can be any proportion of the overall panel. Preferredmaterials include synthetic resin films and metal foils. Optionally, thebase panel includes a handle that projects out from the base panel.Optionally, the base panel includes textured surfaces and/or imprintedgraphics, words, or logos.

The retentive layer is composed of a porous material that can retain thesubstance without substantial product loss, but expels the substancewhen used in its intended manner. The retentive layer material dependson the substance and holds enough for at least one use.

The method for bonding the retentive material to the base panel dependsupon the materials and is accomplished by well-known adhesivetechniques.

After the retentive layer is suffused with the substance, it is sealedwith a removable cover. The cover is preferably composed of a foil ofmetal such as an aluminum alloy, a plastic, or a laminate of metal andplastic. The adhesive is strong enough to maintain a hermetic seal, butweak enough so that the cover can be manually peeled from the basepanel.

Other objects of the present invention will become apparent in light ofthe following drawings and detailed description of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

For a fuller understanding of the nature and object of the presentinvention, reference is made to the accompanying drawings, wherein:

FIG. 1 is an exploded view of one embodiment of the applicator of thepresent invention;

FIG. 2 is an exploded view of a second embodiment of the applicator ofthe present invention;

FIG. 3 is a cross-sectional view of the applicator of FIG. 1 taken alongthe line 3-3;

FIG. 4 is an exploded view of a third embodiment of the applicator ofthe present invention;

FIG. 5 is an exploded view of a fourth embodiment of the applicator ofthe present invention; and

FIG. 6 is a cross-sectional view of the applicator of FIG. 5 taken alongthe line 6-6.

DETAILED DESCRIPTION OF THE INVENTION

The single use applicator 10 of the present invention is constructed bybonding a layer of retentive material 14 to one side of a base panel 12,suffusing the retentive material 14 with an amorphous substance 30, andsealing the retentive material 14 under a cover 16 so that the substance30 remains in the retentive material 14 and free from contamination.Alternatively, the amorphous substance 30 is applied directly to oneside of the base panel 12. The applicator 10 is intended for use withcreams, gels, powders, and other amorphous substances.

The base panel 12 is a sheet composed of materials that are flexible,semi-rigid, or rigid. The area 26 to which the retentive material 14 isadhered is non-porous, not wettable by water, and is insoluble in waterand the substance 30.

Typical flexible, impermeable sheets are synthetic resin films. Theseresin films include polyolefins and polyvinyl copolymers, such aspolyethylene, polypropylene, polybutylene, polyvinyl acetate, polyvinylchloride, polyvinylchloride-vinylidene chloride and the like. Thechlorinated polyvinyl copolymers are highly resistant to degradationcaused by exposure to either water- or alcohol-based fluids. The basepanel 12 may also be composed of metal foils such as an aluminum alloy,a plastic, or a laminate of metal and plastic. A base panel 12 made fromthese materials is flexible, has strength characteristics sufficient toresist tearing and piercing under normal manufacturing and handlingstresses, is nonwettable by water, and can be sterilized and colored.The preferred thickness of the base panel 12 is from about 0.5 mils toabout 80 mils.

Optionally, the base panel 12 extends beyond the retentive materialattachment area 26 to form a handle 28. Optionally, the handle 28 and/orthe surface 20 of the base panel 12 opposite that of the retentive layer14 may include textured surfaces, grips extending from the surface,and/or imprinted graphics, words, or logos.

The retentive layer 14 is composed of a porous material, such as gauzecotton, prepared cotton, other organic fibers such as wood fibers,rayon, open-meshed cloth of varying degrees of fineness, woven andnon-woven synthetic fibers, and foamed polymers such as polyurethane.These materials maintain their integrity when moistened. The retentivelayer 14 is sufficiently retentive to store and apply a useable amountof substance 30. The retentive layer 14 is able to contain the substance30 without extensive or substantial product loss (i.e., dripping), butexpels the substance 30 when the proper pressure is applied or used inits intended manner.

Typically, the thickness of the retentive layer 14 depends upon thematerial and surface area of the applicator 10. Different materials areused appropriately for the application of various substances 30. Theretentive layer 14 holds enough substance 30 for at least oneuse/application. The actual amount that the retentive layer 14 holdsdepends upon the substance 30 and the amount necessary to perform itsfunction adequately, and will typically be in 1 to 10 ml range. Forexample, when the substance 30 is a deodorant, the retentive layer 14will be able to hold 1 to 10 ml of the deodorant.

The method for bonding the retentive material 14 to the base panel 12depends upon the materials of which the base panel 12 and retentivelayer 14 are made, and is accomplished by standard techniques well-knownin the art of adhesives. The bond is resistant to degradation caused byexposure to the substance 30. To achieve a good bond, it is a commonpractice to first degrease or rinse the retentive layer surface 18 ofthe base panel 12 by an organic solvent such as acetone or methyl ethylacetone. Degreasing prepares the surface 18 for bonding.

Because the preferred retentive materials are porous, capable ofabsorbing liquefied polymers, and allow the evaporation of vapor, mostof the standard joining methods using adhesives with or without solventscan be used. A preferred method for joining the base panel 12 to theretentive layer 14 is to apply a thin coat of a molten polyolefin, suchas polyethylene, polypropylene, or polybutylene, onto the retentivelayer surface 18 by extrusion, apply the retentive layer 14 contiguouslyto the retentive layer surface 18, and press them together before thecoat solidifies. Alternatively, instead of applying a thin coat ofpolyolefin by extrusion, the standard rolling technique of directgravure can be used to print the thin coat to selected areas of theretentive layer surface 18. Optionally, the retentive layer 14 isprecoated with a polymer. The molten polyolefin absorbed into theretentive layer 14 will anchor to the base panel 12 and, when cooled,will bind the retentive layer 14 and the base panel 12 together.

Alternatively, the retentive layer 14 is joined to the base panel 12 byapplying a solid powder polyolefin to the retentive layer surface 18 ofthe base panel 12, placing the retentive layer 14 on top of the powder,and subjecting the two to a high-pressure heat seal.

Alternatively, as shown in FIG. 2, the substance 30 applied directly tothe base panel 12. Texturing on the base panel 12 or other supplementarygeometries may assist in the fixation of the substance 30 to the basepanel 12. Optionally, the substance may be adhered in series of shapesincluding, but not limited to, rows, dots, letters and numbers, andsymbols.

After the retentive layer 14 is suffused with the substance 30, it issealed into an enclosed space 22 between the base panel 12 and aremovable cover 16. The space 22 is hermetic so that the retentive layer14 remains moist and uncontaminated by external agents. The space 22remains hermetic for an extended period of time that represents theshelf life of the applicator 10, which includes the period of time fromthe installation of the cover 16, through transportation and storage, touse, when the cover 16 is removed. The cover 16 can be large or smallenough to cover the base panel in its entirety or any portion thereof.

The cover 16 is a planar sheet that is preferably composed of a foil ofmetal such as an aluminum alloy, a plastic, or a laminate of metal andplastic. The cover 16 is robust enough to maintain integrity while beingsubjected to normal stresses throughout transportation, storage, andhandling. The cover 16 is unaffected by water and the substance 30during the shelf life of the applicator 10.

The adhesive used to adhere the cover 16 to the base panel 12 is strongenough to maintain the hermetic seal, but weak enough so that a smallamount of tensional stress, such as that caused by manually peeling thecover 16 from the base panel 12, will cause the adhesive to fracture,allowing the cover 16 to be separated from the base panel 12. Theadhesive is unaffected by water and the substance 30 during the shelflife of the applicator 10. Adhesive materials include urethanes andpolyurethanes.

The embodiment 80 of FIG. 4 can be used with substances that would stickto the cover during removal. The substance 86 is positioned in a capsule88 between the base panel 82 and a capsule cover 84. The peripheral seam94 between the base panel 82 and capsule cover 84 has a weakened section90 adjacent to an application region 92 of the base panel 82. Prior toapplication, the capsule 88 is pressed so that the substance 84 rupturesthe weakened section 90 and squeezes onto an application region 92.

The embodiment of FIGS. 5 and 6 can be used when there is more than onesubstance 62, 64. The substances 62, 64 are separated by positioningthem in the space between the base panel 52 and a capsule cover 66. Thecapsule cover 66 is adhered to the base panel 52 around the edge and ata line between the substances 62, 64, as at 72, creating two capsules68, 70 to house the substances 62, 64. Prior to application, the twocapsules 68, 70 are pressed so that the two substances 62, 64 aresqueezed through a weakened area 76 of the cover/base panel seam andonto the mixing area 60 under the cover 56. The substances 62, 64 aremixed together by massaging the mixing area with the fingers on thecover 56 and base panel 52. Alternatively, the substances 62, 64 aremixed after removing the cover 56 by using an optional wand 74 that isremovably attached to the base panel 52. Alternatively, the substances62, 64 are mixed using the cover 56 after it is removed. Optionally, thecover 56 and the capsule cover 66 are a single sheet.

Optionally, the adhesive may be re-sealable to enable multiple uses ofthe applicator 10. Resealable adhesives materials include acrylics.

Optionally, the cover 16 is vacuum-sealed to alleviate the need forstrong adhesives that would prevent easy removal of the cover.

Optionally, there is a finger tab 24 extending from one edge of thecover 16 that can be grasped between a thumb and finger for ease andconvenience in removing the cover 16 from the base panel 12.

Optionally, the base panel 12 and the cover 16 are composed of thesingle sheet that is folded over.

Optionally, the cover 16 may include textured surfaces and/or imprintedgraphics, words, or logos. The printed graphics may include postage.

Optionally, the applicator 10 is encased in a foil or plastic pouch forincreased protection, marketing/product design, and/or ease oftransportation.

Optionally, the applicator is tessellated for ease of manufacturing anddistribution.

Thus it has been shown and described an applicator which satisfies theobjects set forth above.

Since certain changes may be made in the present disclosure withoutdeparting from the scope of the present invention, it is intended thatall matter described in the foregoing specification and shown in theaccompanying drawings be interpreted as illustrative and not in alimiting sense.

1. An applicator for an amorphous substance comprising: a. a base panelthat is impermeable to said amorphous substance and having a peripheraledge; b. a cover composed of a thin, flexible sheet that is unaffectedby said amorphous substance; c. a cover securing means for securing saidcover to said base panel such that a hermetically closed space iscreated between said base panel and said cover, said cover securingmeans having a tensional stress resistance that permits manual removableof said cover from said base panel; and d. said amorphous substancebeing located within said hermetically closed space.
 2. The applicatorof claim 1 further comprising a retentive layer and a retentive layersecuring means for securing said retentive layer to said base panelwithin said hermetically closed space, said amorphous substance suffusedthroughout said retentive layer.
 3. The applicator of claim 1 whereinsaid base panel includes a handle.
 4. The applicator of claim 1 whereinsaid cover includes a finger tab to facilitate removal.
 5. Theapplicator of claim 1 wherein said base panel and/or said cover isadapted to receive graphics.
 6. The applicator of claim 1 wherein saidbase panel and/or cover is textured.
 7. An applicator for an amorphoussubstance comprising: a. a base panel that is impermeable to saidamorphous substance and having a peripheral edge; b. a cover composed ofa thin, flexible sheet that is unaffected by said amorphous substance;c. a cover securing means for securing said cover to said base panelsuch that a hermetically closed space with a peripheral seam is createdbetween said base panel and said cover; d. said amorphous substancebeing located within said hermetically closed space; and e. saidperipheral seam having a weakened portion wherein squeezing said coverand said base panel adjacent to said closed space causes said weakenedportion to rupture and expel said amorphous substance.
 8. The applicatorof claim 7 wherein said base panel includes a handle.
 9. The applicatorof claim 7 wherein said base panel and/or cover is adapted to receivegraphics.
 10. The applicator of claim 7 wherein said base panel and/orcover is textured.
 11. A method of producing an applicator for anamorphous substance comprising the steps of: a. providing a base panelthat is impermeable to said amorphous substance and that has aperipheral edge; b. positioning a quantity of said amorphous substanceon said base panel; and c. securing a cover that is composed of a thin,flexible sheet that is unaffected by said amorphous substance to saidbase panel such that said amorphous substance is contained within ahermetically closed space between said base panel and said cover, saidcover securing means having a tensional stress resistance that permitsmanual removable of said cover from said base panel.
 12. The method ofclaim 11 further comprising the steps of securing a retentive layerhaving a peripheral edge to said base panel such that said retentivelayer peripheral edge is spaced inwardly from said base panel peripheraledge, and suffusing said amorphous substance throughout said retentivelayer prior to securing said cover.
 13. The method of claim 11 whereinsaid base panel is provided with a handle.
 14. The method of claim 11wherein said cover is provided with a finger tab to facilitate removal.15. The method of claim 11 further comprising imprinting graphics onsaid base panel and/or said cover.
 16. The method of claim 11 furthercomprising texturing said base panel and/or said cover.